Method and actuation control for stopping an electrical drive, by means of closed-loop position control, in a predetermined nominal position

ABSTRACT

The invention reduces the oscillation of the rotation speed regulator when stationary—despite low position resolution and a high minimum rotation speed resulting from this—by switching the closed-loop control structure, when the drive is moved into the nominal position, in which case the closed-loop control structure does not need to include a current regulator when stationary. The control voltage is predetermined directly by the rotation speed regulator ( 2′ ), which is in the form of a pure P-regulator. If the rotor is deflected, then dynamic negative feedback is carried out by differentiation ( 9 ) of the position (φ). The position control loop ( 1′ ), which is at a higher level than the rotation speed control loop ( 2′ ), is in the form of a PI regulator in order that no permanent position errors can occur. The switching of the closed-loop control structure according to the invention is achieved by producing characteristics which are optimized as a function of the state, namely high dynamics during movement and a good unmoving position when stationary.

FIELD OF THE INVENTION

[0001] The invention relates to a method for stopping an electrical drive, by means of closed-loop position control, in a predetermined nominal position, and to corresponding drive control.

[0002] In drives with closed-loop position control and a conventional, cascaded closed-loop control structure, low position resolution, when also used for rotation speed control, when stationary by means of closed-loop position control, often leads to undesirable “oscillation” of the rotation speed regulator.

[0003] As a rule, this oscillation is associated with low position resolution and position sampling at discrete times which leads to “minimum quantization” of the rotation speed, which energizes the rotation speed regulator when new position information occurs. This results in position deflection, which the position regulator has to counteract.

[0004]FIG. 1 shows a block diagram of such a known conventional cascade closed-loop control structure, in which this problem can occur. In this structure, PI current control 3 forms the innermost control loop, by supplying a control voltage u_(s) for control equipment 4 in order to produce actuation signals for the electric motor (for example for the active power devices in a three-phase bridge inverter for a three-phase machine). The actual current value i which occurs in the armature circuit 5 whose input side is actuated by the motor voltage u is fed back negatively to the input of the current regulator 3.

[0005] At a higher level, there is a PI rotation speed regulator 2, whose associated actual rotation speed value n, which is likewise fed back negatively to the input, is formed by differentiation of the actual position value φ. The output of the rotation speed regulator 2 with the nominal current value i_(s) by limiting 8 to the maximum permissible current i_(max.)

[0006] The outer control loop is formed by a P-position regulator 1 whose nominal position value φ_(s) is predetermined by higher-level path control (not shown).

[0007] An actual position value φ is likewise fed back negatively to the input of the position regulator 1.

[0008] Drives having a positioning capability are nowadays normally provided by using DC motors with or without brushes, or synchronous motors with permanent-magnet excitation. As a rule, the actual position value is formed via an incremental sensor with a downstream step-up/down counter 7, whose input is actuated by a mechanical integrator 6. The mechanical integrator 6 has actual current values i applied to it, and describes the physical relationship between the rotation speed n and the torque M in accordance with $\omega = {\frac{1}{J} \cdot {\int{{M \cdot {t}}\quad {where}}}}$

ω=2·π·n, M≈i,

[0009] which results in the following relationship:

n=K·∫i·dt.

[0010] The overall open-loop sequence control and closed-loop control are preferably carried out digitally in a microprocessor, with the individual control loops 1,2 and 3 being calculated cyclically at fixed time intervals, and with the cycle time of a respective low-level control loop having to be less than or equal to that of the higher-level control loop.

[0011] In the past, this undesirable state has been solved and good stationary response with closed-loop position control has been achieved either by the incremental sensor having very high position resolution or by low gains in the position and rotation speed control loops.

[0012] Increased position resolution thus reduces the minimum rotation speed, which is governed by the quantization. Implementation with high position resolution in order to minimize the rotation speed quantization results, however, in expensive sensor systems with small quantization intervals, which also have to be evaluated “in a complex manner” by interpolation, which cannot be done cost-effectively in all applications.

[0013] On the other hand, reducing the gains in the position and rotation speed control loops reduces the control quality, particularly when load torques are present. If the motor has magnetic cogging torques, undesirable compensation movements can occur.

[0014] The object of the present invention is thus to provide closed-loop control in which this undesirable oscillation of the rotation speed regulator when the motor is stationary is avoided, despite low position resolution.

[0015] According to the present invention, this object is achieved by a method for stopping an electrical drive, by means of closed-loop position control, in a predetermined nominal position by switching a closed-loop control system for movement operation and after reaching the predetermined nominal position to position-maintenance closed-loop control, having rotation speed control with a proportional element and higher-level position control with a proportional element and an integral element.

[0016] According to a first advantageous refinement of the method according to the present invention, current limiting is carried out after reaching a predetermined nominal position and until the next movement instruction, in that, if a predetermined current limit value is exceeded in the armature circuit of the drive, the control voltage for the rotation speed control is limited.

[0017] For implementation of the method according to the invention, it has been found to be advantageous for the proportional gain of rotation speed control to be optimized to the mass moment of inertia of the electric motor being used.

[0018] For the proportional gain and the integral-action time of the integral element of the closed-loop position control, it is recommended that these items be permanently set to the controlled system of the position-maintenance closed-loop control.

[0019] For integration of the method according to the invention in an existing control system of an electrical drive with closed-loop position control, this drive is moved to a respective nominal position, according to a further advantageous refinement, with cascade closed-loop control by means of current control, higher-level rotation speed control and even higher-level position control, in which case, after reaching this predetermined nominal position and until the next movement instruction, the drive is controlled by modified cascade closed-loop control without current regulation as described above.

[0020] In this case, it has been found to be advantageous if, in order to avoid discontinuities when switching between movement operation and position-maintenance closed-loop control, the integral elements of the respective control structure which are not required are set to zero.

[0021] Furthermore, the object of the invention is also achieved by drive control for stopping an electrical drive, by means of closed-loop position control, in a predetermined nominal position, with a cascade closed-loop control structure comprising a P-regulator for rotation speed control which is used to produce a control voltage for control equipment for the drive, and having a higher-level PI regulator for closed-loop position control.

[0022] Such drive control according to the invention is particularly effective if the actual position values can be obtained by means of an incremental sensor with a downstream counter, and actual rotation speed values can be determined from this by a means for differentiation.

[0023] A further advantageous refinement of this drive control according to the invention additionally comprises a means for limiting the control voltage on the output side of the P-regulator by an integrator when a predetermined current limit value is exceeded in the armature circuit of the drive.

[0024] The method according to the invention and the drive control according to the invention thus reduce the oscillation of the rotation speed regulator when stationary—despite low position resolution and a high minimum rotation speed resulting from this—by switching the closed-loop control structure when the drive has moved to the nominal position.

[0025] The exemplary embodiment which is described in the following text is used to explain further details and advantages of the invention with reference to a block diagram of a closed-loop control structure according to the invention. In the outline illustration:

[0026]FIG. 1 shows a block diagram of a conventional cascade closed-loop control structure for controlling movements for an electrical drive with closed-loop position control, and

[0027]FIG. 2 shows a block diagram of a closed-loop control structure according to the invention for switching when stationary.

[0028] The conventional closed-loop control structure shown in FIG. 1 which has already been explained initially is very highly suitable for carrying out movements. However, if the movement speed is so low that the incremental sensor 7 no longer supplies at least one position increment in each rotation speed regulator cycle, then it is no longer possible to form a continuous actual rotation speed value n over time, by differentiation.

[0029] Particularly when stationary, this leads to a situation in which the gain in the rotation speed control loop must be reduced from the optimum values, thus also limiting the position regulator gain which can be set. Position errors which are caused by disturbance and cogging torques (for example magnetic cogging torques) can thus be compensated for less well.

[0030] When the drive has moved to a predetermined nominal position, higher-level sequence control (not shown), for example a numerical control NC, switches, according to the invention, to a regulator structure as shown in FIG. 2, whose object is to maintain this position as well as possible until the next movement starts.

[0031] This can be achieved particularly easily if the closed-loop control structure is calculated digitally in a microporcessor or microcontroller since, then, all that is necessary is to redefine the closed-loop control model in the software.

[0032] As can be seen from the block diagram of a closed-loop control structure according to the invention as shown in FIG. 2, this structure does not need any current regulator. The control voltage is predetermined directly by the rotation speed regulator 2′. In contrast to the conventional cascade regulator structure shown in FIG. 1, this is in the form of a pure P-regulator with a proportional element, but without any integral element. This rotation speed regulator 2′ thus directly supplies the control voltage u_(s) for the control equipment 4. The rest of the construction of the armature circuit 5, of the mechanical integrator 6 and of the rotor position detection by means of the incremental sensor with a step-up/down counter 7 corresponds to that in FIG. 1.

[0033] As long as the drive is stationary in the nominal position, this drive remains absolutely stationary by virtue of the closed-loop control structure shown in FIG. 2, having a rotation speed regulator 2′ without an integral element.

[0034] If the rotor of the motor is deflected, for example by external influences, then differentiation 9 of the position φ results in dynamic negative feedback. The position control loop, which is at a higher level than the rotation speed control loop, is in the form of PI regulator 1′ in order that no residual position errors can occur. In comparison to the conventional closed-loop control structure for movements as shown in FIG. 1, the position regulator 1′ according to the invention now has an integral part, with the function that has been explained, in addition to the known proportional part.

[0035] The testing and the changes of the regulator structures as shown in FIG. 1 and FIG. 2 are carried out, for example, in a rotation speed nominal value output n_(s), which is called cyclically. When switching to the position-maintenance regulator (FIG. 2), the position-maintenance nominal value required on activation is formed using the following formula: ${{Nominal}\quad {maintained}\quad {position}} = {{{actual}\quad {position}} - \frac{{Slip}\quad {distance}}{{Increment}\quad {movement}}}$

[0036] If the “nominal maintenance position” overflows, overflow correction must be carried out.

[0037] The rotation speed control is preferably implemented using the fastest time slice (for example 125 μs) using a P-regulator whose gain is optimized to the mass moment of inertia of the motor being used. The inner control loop allows a good stationary behavior despite low actual position value resolution. The P-gain is preset as a function of the specific motor. The P-gain can be adapted by the end user, if required.

[0038] The actual rotation speed value calculation is carried out as follows: ${n\_ ist} = {\frac{{lage\_ aktuell} - {lage\_ alt}}{Zykluszeit}\left\lbrack {{n - {act}} = \frac{{{present}\quad {position}} - {{old}\quad {position}}}{cycletime}} \right\rbrack}$

[0039] The outer PI position control loop 1′ ensures that it is impossible for any permanent control errors to remain. The proportional gain and the integral-action time, or the integral element, are permanently set to the controlled system. The control loop gains are in this case preferably reduced such that operation with external flywheel masses up to 3 times the motor mass moment of inertia is possible without any problems. In “exotic” applications with even higher mass moments of inertia, the proportional gain of the inner rotation speed control loop 2′ must be increased as appropriate.

[0040] The current regulator is superfluous, and is omitted here for computation time reasons. However, the current limiting should still be active. An integrating current limiter 10 is thus activated. This operates, for example, in the background of the application.

[0041] The current limiting still remains active in that, if the limit value i_(max) is exceeded, the voltage limiting 8′ for the control voltage us supplied on the output side from the rotation speed regulator 2′ is tightened via an integrator 10.

[0042] The regulator structure according to the invention, which is simpler than the conventional cascade regulator structure shown in FIG. 1, allows the entire position closed-loop control to be calculated in a shorter cycle time. In order that the switching between normal operation and position-maintenance closed-loop control can take place without any discontinuities, the integral elements of the respective regulator structure which is not required are set to zero. This is the PI position regulator 1′ when stationary, and the rotation speed regulator 2 and the current regulator 3 for movement operation.

[0043] The switching of the closed-loop control structure according to the invention thus results in optimized characteristics being produced as a function of the state, namely: high dynamics during movement and good position rest when stationary. 

1. A method for stopping an electrical drive, by means of closed-loop position control, in a predetermined nominal position by switching a closed-loop control system (1, 2, 3, 8, 9) for movement operation and after reaching the predetermined nominal position to position-maintenance closed-loop control, having rotation speed control (2′) with a proportional element and higher-level position control (1′) with a proportional element and an integral element.
 2. The method for stopping an electrical drive, by means of closed-loop position control, as claimed in claim 1, in which current limiting (8′,10) is carried out after reaching a predetermined nominal position and until the next movement instruction, in that, if a predetermined current limit value (i_(max)) is exceeded in the armature circuit of the drive, the control voltage (u_(s)) for the rotation speed control (2′) is limited.
 3. The method for stopping an electrical drive, by means of closed-loop position control, as claimed in claim 1 or 2, in which case the proportional gain of the rotation speed control (2′) is optimized to the mass moment of inertia of the electrical motor being used.
 4. The method for stopping an electrical drive, by means of closed-loop position control, as claim 1, in which the propulsional gain and the integral-action time of the integral element of the closed-loop position control are set permanently to the controlled system of the position-maintenance closed-loop control.
 5. A method for controlling an electrical drive with closed-loop position control, in which case a respective nominal position is approached using cascade closed-loop control by means of current control (3), higher-level rotation speed control (2) and even higher-level position control (1), in which case, after reaching a predetermined nominal position and until the next movement instruction, the drive is controlled according to one of the preceding claims using modified cascade closed-loop control (1′,2′,8′,10), in particular without current control.
 6. A method for controlling an electrical drive with closed-loop position control, in which case, in order to avoid discontinuities when switching between movement operation and position-maintenance closed-loop control, the integral elements of the respective control structure (2, 3 or 1′) which are not required are set to zero.
 7. Drive control for stopping an electrical drive, by means of closed-loop position control, in a predetermined nominal position, having a cascade closed-loop control structure comprising a P-regulator (2′) for rotation speed control, which is used to produce a control voltage (u_(s)) for control equipment (4) for the drive, and having a higher-level PI regulator (1′) for closed-loop position control.
 8. The drive control for an electrical drive with closed-loop position control as claimed in claim 7, in which case actual position values (φ) can be obtained by means of an incremental sensor with downstream counter (7), and actual rotation speed values (n) can be determined from this (φ) by a means for differentiation (9).
 9. The drive control for an electrical drive with closed-loop position control as claimed in claim 7 or 8, having a means for limiting (8′) the control voltage (u_(s)) on the output side of the P-regulator (2′) by an integrator (10) when a predetermined current limit value (i_(max)) is exceeded in the armature circuit of the drive. 